Miller Big Blue 450 Duo CST Owner's Manual
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Miller Big Blue 450 Duo CST Owner's Manual

Miller Big Blue 450 Duo CST Owner's Manual

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Big Blue
CST
OWNER'S MANUAL
OM-266621G
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Engine Driven Welder/Generator
450 Duo
®
2023-03

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  • Page 1 OM-266621G 2023-03 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Engine Driven Welder/Generator Big Blue 450 Duo ® OWNER’S MANUAL For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING..............1 Symbol Usage .
  • Page 4 TABLE OF CONTENTS Front Panel CST Controls ................... 35 SECTION 7 –...

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! – Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 Accidental contact of electrode to metal objects can cause sparks, ex- FLYING METAL OR DIRT can injure plosion, overheating, or fire. Check and be sure the area is safe be- eyes. fore doing any welding. � Welding, chipping, wire brushing, and grinding �...

  • Page 7: Engine Hazards

    � Install cylinders in an upright position by securing to a stationary � Turn face away from valve outlet when opening cylinder valve. Do support or cylinder rack to prevent falling or tipping. not stand in front of or behind the regulator when opening the valve.

  • Page 8: Compressed Air Hazards

    1-4. Compressed Air Hazards � Reinstall doors, panels, covers, or guards when servicing is fin- COMPRESSED AIR EQUIPMENT can ished and before starting unit. injure or kill. � If ANY air is injected into the skin or body seek medical help immediately.
  • Page 9 � Follow the guidelines in the Applications Manual for the Revised HIGH PRESSURE FLUIDS can injure NIOSH Lifting Equation (Publication No. 94-110) when manually or kill. lifting heavy parts or equipment. � Engine fuel system components can be under high OVERHEATING can damage motors.

  • Page 10: California Proposition 65 Warnings

    � If notified by the FCC about interference, stop using the equipment � Be sure all equipment in the welding area is electromagnetically at once. compatible. � Have the installation regularly checked and maintained. � To reduce possible interference, keep weld cables as short as �...

  • Page 11: Section 2 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 � Ne pas toucher aux portes-électrodes qui sont raccordés à deux bien ventilé, et en portant un respirateur à alimentation d’air. Les machines à souder en même temps, car cela entraîne la présence revêtements et tous les métaux renfermant ces éléments peuvent d’une tension de circuit-ouvert double.

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    � Ne pas souder là où l’air ambiant pourrait contenir des poussières, � Les porteurs d’implants médicaux doivent consulter leur médecin gaz ou émanations inflammables (vapeur d’essence, par et le fabricant du dispositif avant de s’approcher de la zone où se exemple).

  • Page 14: Dangers Liés À L'air Comprimé

    � Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces � Ne pas toucher aux pièces chaudes, utiliser les outils recomman- inflammables. dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. � Tenir à distance les produits inflammables de l’échappement. LA VAPEUR ET LE LIQUIDE DE Les PIÈCES MOBILES peuvent REFROIDISSEMENT CHAUD peuvent...

  • Page 15: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    L’AIR COMPRIMÉ risque de Les PIÈCES MOBILES peuvent provoquer des blessures ou même la causer des blessures. mort. � S’abstenir de toucher des parties mobiles telles � Avant d’intervenir sur le circuit d’air comprimé, que des ventilateurs, courroies et rotors. couper l’alimentation électrique, verrouiller etéti- �...
  • Page 16 � Utiliser uniquement des équipements adéquats pour un fonction- � Régler les commandes de charge de batterie sur la position d’arrêt nement avec une alimentation de 50/60 ou de 60 Hz. avant de brancher la batterie. Veiller à ce que les pinces de charge ne se touchent pas.

  • Page 17: Proposition Californienne 65 Avertissements

    � Effectuer l’installation, l’entretien et toute intervention selon les LE SOUDAGE À L’ARC risque de manuels d’utilisateurs, les normes nationales, provinciales et de provoquer des interférences. l’industrie, ainsi que les codes municipaux. � L’énergie électromagnétique risque de provoquer LE RAYONNEMENT HAUTE des interférences pour l’équipement électronique FRÉQUENCE (H.F.) risque de sensible tel que les ordinateurs et l’équipement...
  • Page 18 les porteurs d’implants médicaux doivent être prises: par exemple, 5. Connecter la pince sur la pièce aussi près que possible de la des restrictions d’accès pour les passants ou une évaluation indivi- soudure. duelle des risques pour les soudeurs. Tous les soudeurs doivent ap- 6.

  • Page 19: Section 3 - Definitions

    Some symbols are found only on CE products. facility. Some symbols are found only on CE products. Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Contact your local recycling office or your local distributor for further information. Safe �...
  • Page 20 Turn off power before disassembling torch. � Complete Parts List is available at www.MillerWelds.com Safe19 201 Do not remove or paint over (cover) the label. Do not remove or paint over (cover) the label. Safe20 201 Writer: If necessary, replace the word “handle” with “lift eye’. Do not use one handle to lift or support unit.
  • Page 21 Engine fuel plus flames or sparks can cause fire. Engine fuel plus flames or sparks can cause fire. Safe7 2017 04 Safe7 2017 04 � Complete Parts List is available at www.MillerWelds.com Safe45 2012 05 Safe45 2012 05 Become trained and read the instructions before working on the Become trained and read the instructions before working on the machine or welding.

  • Page 22: Miscellaneous Symbols And Definitions

    Hot muffler and exhaust pipe can cause severe burns. Hot muffler and exhaust pipe can cause severe burns. Hot muffler and exhaust pipe can cause severe burns. � Complete Parts List is available at www.MillerWelds.com Safe90 2017 Safe90 201 Safe90 2017 Welding, cutting, drilling, or grinding on base can cause fire or Welding, cutting, drilling, or grinding on base can cause fire or explosion.
  • Page 23 � Complete Parts List is available at www.MillerWelds.com Check Engine Belt Positive Hour Meter Tension Call For Maintenance Negative Hours Read Operator’s Engine Oil 1/2 in. Engine Manual (13 mm) Air Filter Engine Coolant Engine Check Injectors/ Fuel Check Air Cleaner Pump Certified/Trained Mechanic...

  • Page 24: Section 4 - Specifications

    Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 25: Environmental Specifications

    Complete Parts List is available at www.MillerWelds.com � For information on specifications and performance data pertaining to standard CST units operating individually, see Miller Owner’s Manual OM-217655. Use this Owner’s Manual in conjunction with OM-217655 for operation, maintenance, and troubleshooting.

  • Page 26: Volt-Ampere Curves: Stick

    C. Stick Volt-Ampere Curves C. Stick Volt-Ampere Curves � Complete Parts List is available at www.MillerWelds.com 4-8. Volt-Ampere Curves: Stick XX10 Stick Mode XX10 Stick Mode The volt-ampere curves show the minimum XX10 Stick Mode and maximum voltage and amperage output capabilities of the welding generator.

  • Page 27: Volt-Ampere Curves: Tig

    � Complete Parts List is available at www.MillerWelds.com Complete Parts List is available at www.MillerWelds.com 4-9. Volt-Ampere Curves: TIG D. TIG Volt Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves Complete Parts List is available at www.MillerWelds.com shown.

  • Page 28: Section 5 - Installation

    � Complete Parts List is available at www.MillerWelds.com SECTION 5 – INSTALLATION 5-1. Installing Welder/Generator Movement And Airflow Clearance 18 in. 18 in. (460 mm) (460 mm) 18 in. 18 in. (460 mm) 18 in. 18 in. (460 mm) (460 mm) (460 mm) 18 in.

  • Page 29: Grounding Generator To Truck Or Trailer Frame

    1-1. Installing Exhaust Pipe � Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator to Truck or Trailer Frame 1-1. Grounding Generator To Truck Or Trailer Frame GND/PE Bed liners, shipping skids, and 3 Metal Vehicle Frame Always ground generator frame to some running gear insulate the vehicle frame to prevent electric welding generator from the vehicle...

  • Page 30: Connecting The Battery

    Keep battery in good condition. Store during run-in, see Section 11. Automatic Shutdown System battery in warm area. NOTICE – Diesel engines in Miller equip- ment are meant to operate optimally at mod- Use fuel formulated for cold weather Automatic shutdown system stops engine if (diesel fuel can gel in cold weather).

  • Page 31: Engine Fuel And Coolant Prestart Information

    � Complete Parts List is available at www.MillerWelds.com 1-3. Engine Fuel And Coolant Prestart Information 5-6. Engine Fuel And Coolant Prestart Information Ref: 907 427 6 2 Check coolant level in radiator before start- coolant if level is below bottom of radiator Fuel ing unit the first time.

  • Page 32: Mitsubishi Engine Oil Prestart Information

    � Complete Parts List is available at www.MillerWelds.com 5-7. Mitsubishi Engine Oil Prestart Information Complete Parts List is available at www.MillerWelds.com Check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).

  • Page 33: Weld Output Terminals

    � Complete Parts List is available at www.MillerWelds.com 5-9. Weld Output Terminals Complete Parts List is available at www.MillerWelds.com 1-4. Weld Output Terminals Turn off power before connecting to weld output terminals. Do not use worn, damaged, under- sized, or repaired cables. 1 Positive (+) Weld Output Terminal 2 Negative (-) Weld Output Terminal �...

  • Page 34: Making Dual Operator Cc Weld Connections With Common Work Cables

    1-5. Making Dual Operator CC Weld Connections With Common Work Cables � Complete Parts List is available at www.MillerWelds.com 5-10. Making Dual Operator CC Weld Connections With Common Work Cables 907 477 / Ref. 801 701 NOTICE – When using these connections For Stick/TIG welding Direct Current Elec- Stop engine.

  • Page 35: Paralleling Cst Units For Smaw Welding

    1-6. Paralleling CST Units For SMAW Welding � Complete Parts List is available at www.MillerWelds.com 5-11. Paralleling CST Units For SMAW Welding 907 477 / Ref. 801 701 NOTICE – When using these connections For Stick welding Direct Current Electrode Stop engine.

  • Page 36: Section 6 - Operation

    � Complete Parts List is available at www.MillerWelds.com SECTION 6 – OPERATION Complete Parts List is available at www.MillerWelds.com 6-1. Front Panel Engine Controls SECTION 2 OPERATION 2-1. Front Panel Engine Controls (See Section NO TAG) 907 477 / Ref 264 783 Above 32°...

  • Page 37: Operating Optional Engine Block Heater

    � Complete Parts List is available at www.MillerWelds.com 6-2. Operating Optional Engine Block Heater 1 Engine Block Heater Plug Use heater to maintain a constant engine coolant temperature. To turn on heater, connect heater plug to 120 volts AC receptacle. Do not run engine while engine block heater is on.

  • Page 38: Fuel/Hour Gauge Descriptions

    Complete Parts List is available at www.MillerWelds.com � Complete Parts List is available at www.MillerWelds.com 6-3. Fuel/Hour Gauge Descriptions 2-2. Fuel/Hour Gauge Descriptions OM-266621 Page 34 OM-266621 Page 9...

  • Page 39: Front Panel Cst Controls

    � Complete Parts List is available at www.MillerWelds.com 6-4. Front Panel CST Controls Complete Parts List is available at www.MillerWelds.com A. Overview 2-3. Front Panel CST Controls A. Overview Ref. 217 192-B / 803 942-A illuminates continuously. When unit is shut 5 High Temperature Shutdown Light �...
  • Page 40 Ref. 217 192-B / 803 942-A � Complete Parts List is available at www.MillerWelds.com B. Process Select Control B. Process Select Control 1 Process Select Control Rotate knob to select desired process. Lift-Arc ™ TIG- Normal open-circuit voltage is not present between the electrode and work- piece.

  • Page 41: Section 7 - Operating Auxiliary Equipment

    Complete Parts List is available at www.MillerWelds.com � SECTION 3 OPERATING AUXILIARY EQUIPMENT Complete Parts List is available at www.MillerWelds.com SECTION 7 – OPERATING AUXILIARY EQUIPMENT 3-1. Generator Power Receptacles 7-1. Generator Power Receptacles 264 783 Test GFCI monthly. See Section 7-2 not work.

  • Page 42: Gfci Receptacle Information, Resetting, And Testing

    � Complete Parts List is available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting, And Testing Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles auxiliary equipment. If unit does not button pops out, and the circuit opens to dis- If a GFCI fault occurs, stop engine and dis- have GFCI receptacles, use GFCI- connect power to the faulty equipment.

  • Page 43: Section 8 - Maintenance And Troubleshooting

    Complete Parts List is available at www.MillerWelds.com � Complete Parts List is available at www.MillerWelds.com SECTION 4 MAINTENANCE & TROUBLESHOOTING SECTION 8 – MAINTENANCE AND TROUBLESHOOTING Maintenance Label 8-1. Maintenance Label OM-266621 Page 13 OM-266621 Page 39...

  • Page 44: Routine Maintenance

    This flowchart is intended as a general guide only. Al- ways read and follow the safety information and specific � Complete Parts List is available at www.MillerWelds.com instructions given elsewhere in this Technical Manual. 8-2. Routine Maintenance owered welder/generator, always perform the following basic before contacting the engine manufacturer.

  • Page 45: Cleaning Unit

    � Complete Parts List is available at www.MillerWelds.com Addison, IL 60101 630-268-0750 https://www.mtea-us.com/ Use website to locate closest dealer. For international information, use: https://www.mhi.com/ 8-3. Cleaning Unit Clean unit exterior, including stainless steel if so equipped, frequently to prevent rust. NOTICE –...

  • Page 46: Servicing Air Cleaner

    � Complete Parts List is available at www.MillerWelds.com NOTE: This standard is now used for IED/PED models with plastic air cleaner housing. 8-4. Servicing Air Cleaner Stop engine. NOTICE – Do not run engine without air cleaner or with dirty element. Engine dam- age caused by using a damaged element is not covered by the warranty.

  • Page 47: Checking Generator Brush Assembly

    minimum length. Check length from brushholder surface. � Complete Parts List is available at www.MillerWelds.com 8-6. Checking Generator Brush Assembly Ref 205725 4 Damaged Brush Replace assembly if brushes are damaged Stop engine and let cool. or if brush material is at or near minimum length.

  • Page 48: Servicing Engine Cooling System

    � Complete Parts List is available at www.MillerWelds.com 8-8. Servicing Engine Cooling System Stop engine and let cool. 1 Radiator Cap Cover 2 Radiator Draincock 3 Coolant Recovery Tank Change coolant according to engine manual. Add coolant according to engine mainte- nance label.

  • Page 49: Servicing Fuel And Lubrication Systems

    � Complete Parts List is available at www.MillerWelds.com 8-10. Servicing Fuel And Lubrication Systems Complete Parts List is available at www.MillerWelds.com 4-2. Servicing Fuel And Lubrication Systems Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel.

  • Page 50: Overload Protection

    6 Supplementary Protector CB3 Primary fuses are 30 A, 250 V, Slo Blo protector. fuses, Miller Part No. 247869. 7 Circuit Breaker CB1 2 Fuse Block For Left CST(as facing front CB1 protects the engine battery circuit. If panel) CB1 opens, the engine will not crank.

  • Page 51: Troubleshooting Cst

    � Complete Parts List is available at www.MillerWelds.com 8-12. Troubleshooting CST Complete Parts List is available at www.MillerWelds.com 1 Output LED (Blue) 2 High Temperature LED (Yellow) 803 942-A OM-266621 Page 47...
  • Page 52 � Complete Parts List is available at www.MillerWelds.com Repeated LED Flashes Indicate Trouble Possible Causes Remedy Status Blue Yellow None None No weld output; Blown fuses. Check and replace line fuses, if neces- unit completely sary . inoperative. Alternating Blue Alternating Blue Process Select switch is between Verify Process Select switch is not be-...

  • Page 53: Troubleshooting Generator

    � Complete Parts List is available at www.MillerWelds.com Repeated LED Flashes Indicate Trouble Possible Causes Remedy Status Blue Yellow Open secondary Have Factory Authorized Service Agent thermistor. check thermistor on output heatsink and associated wiring for opens. Shorted secon- Have Factory Authorized Service Agent dary thermistor.
  • Page 54 � Complete Parts List is available at www.MillerWelds.com Trouble Remedy Reset supplementary protector CB2 and/or clear fault causing circuit breaker CB1 to trip (see Sec- tion 8-11). Have Factory Authorized Service Agent check engine alternator, fuel pump, and engine harness. Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, inte- grated rectifier SR2, and the fuel pump.

  • Page 55: Section 9 - Parts List

    � Complete Parts List is available at www.MillerWelds.com SECTION 9 – PARTS LIST 9-1. Recommended Spare Parts Item No. Dia. Mkgs. Part No. Description Quantity 085874 Fuse, Mintr Cer Slo-blo 10 Amp 250 Volt 244290 Brushholder Assembly, Generator w/Leads 252782 Filter Kit, Mitsubishi (S4l2) (Includes) 252781 —Filter, Fuel Spin-on...

  • Page 56: Section 10 - Electrical Diagrams

    SECTION 10 – ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welder OM-266621 Page 52...
  • Page 57 285601-A OM-266621 Page 53...

  • Page 58: Section 11 - Run-In Procedure

    SECTION 11 – RUN-IN PROCEDURE NOTICE – Diesel engines in Miller equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended peri- ods of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.

  • Page 59: Run-In Procedure Using Load Bank Or Resistance Grid

    11-2. Run-In Procedure Using Load Bank Or Resistance Grid Stop engine. 3 Weld Cables Set grid switches and then adjust gener- ator A/V control so load equals rated 4 Resistance Grid Do not touch hot exhaust pipe, en- voltage and current of the generator (see gine parts, or load bank/grid.

  • Page 60: Section 12 - Generator Power Guidelines

    SECTION 12 – GENERATOR POWER GUIDELINES � The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 12-1. Selecting Equipment 1 Generator Power Receptacles – Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated...
  • Page 61 12-3. Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable GND/PE Use #8 AWG or larger insulated copper wire. 3 Ground Device � Use ground device as stated in electri- cal codes. Ground generator to system earth ground if supplying power to a premises (shop,...
  • Page 62 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 63 12-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment Rating Starting Watts Running Watts Hand Drill 1/4 in. 3/8 in. 1/2 in. Circular Saw 6-1/2 in. 7-1/4 in. 8-1/4 in. 1400 1400 Table Saw 9 in. 4500 1500 10 in. 6300 1800 Band Saw...
  • Page 64 12-8. Power Required To Start Motor 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage AC MOTOR VOLTS AMPS Step 1: Find code and use table to find kVA/ CODE HP. If code is not listed, multiply running am- PHASE perage by six to find starting amperage.
  • Page 65 12-10. Typical Connections To Standby Power 1. Utility Electrical 2. Transfer Switch 3. Fused Disconnect 4. Welder/Generator Service Switch (If Required) Output 5. Essential Loads Have only qualified persons perform 1 Utility Electrical Service 4 Welder/Generator Output these connections according to all 2 Transfer Switch (Double-Throw) Generator output voltage and wiring must applicable...
  • Page 66 12-11. Selecting Extension Cord (Use Shortest Cord Possible) A. Cord Lengths For 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm Current (Amperes)
  • Page 67 Effective January 1, 2023 (Equipment with a serial number preface of ND or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. � CoolBelt, PAPR Blower, and PAPR Face...
  • Page 68 Appleton, WI 54914 USA tact your distributor and/or equipment manu- facturer’s Transportation Department. International Headquarters–USA USA Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2023-03...

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